Door Post Replacement

[ShoeSlinger]

Top half is in perfect shape, and fair overall. Cut out the rust and am debating on replacing full door post or just the cut out portion including the lower door hinge backing. So repair or replace the entire door post? I have done a few of them before with success but still dread it.

 

[fordguy]

I replaced the lower part on mine, tops were perfect. I used a pair of new post and made patch panels by making tabs on the patch and then welding it. I will post a link to my thread later.

 

[ShoeSlinger]

Greatly appreciate it @fordguy.

 

[cldonley]

Mine was in similar shape, and I welded it up with sheet metal-works great. BUT-I didn't cut out as much as you, so Fordguy's idea is a good one.

 

[fordguy]

see post 49 in this thread http://classicbroncos.com/forums/showthread.php?t=188757&highlight=it's+official+build&page=4 that side is not going to be visible

 

[ShoeSlinger]

Thanks @fordguy. I am about to do the same to my passenger side cowl. I figure I will make a few extras since it will only take a little extra time.

 

[rjrobin2002]

I have done several like you are wanting to do. I just cut out the section you did, put a piece of cardboard against it and make a template, then go cut it out of some .100 sheetmetal and weld it in. Then grind and paint black and its looks like new.

I never replaced the front section, just cut some new small pieces to tie the front part to the back and welded them in before I closed it up with the last piece.

 

[mattyq17]

I am in the same boat on the drivers side, I will be attempting to do it the end of March some time. The front of mine is rusted thru in a couple spots around the backing plate area.

 

[74 Bronco Billy]

I had to replace mine they were in such bad shape. If I had this much left, I would also patch, but 1st clean out as much rust as possible, weld in one side with the harvested portion from a replacement pillar, and then paint the back side with POR 15 or some other Rust preventative. That are is one of the two or three worst areas to rust on a Bronco, and once you have to replace an "A" pillar, you will never want to do it again due to the difficulty in keeping things square. Ask me how I know. %)%)

 

[rydog1130]

replace bottom....way easier